Uniform delivery of compositions

ABSTRACT

A system for uniformly delivering treatment compositions to fabrics in a fabric article drying appliance. The system also provides for efficient delivery of treatment compositions to fabrics in a fabric article drying appliance. A method is also provided for the uniform and efficient delivery of treatment compositions to fabrics in fabric article drying appliances.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 11/123,306, filed on May 6, 2005; which claims the benefit ofU.S. Provisional Application Ser. No. 60/568,771, filed on May 6, 2004and is a continuation-in-part of U.S. application Ser. No. 10/842,926,filed on May 11, 2004; which is a continuation-in-part of U.S.application Ser. No. 10/839,549, filed on May 5, 2004; which is acontinuation-in-part of U.S. application Ser. No. 10/762,152, filed onJan. 21, 2004; which is a continuation-in-part of U.S. application Ser.No. 10/697,736, filed on Oct. 29, 2003; U.S. application Ser. No.10/697,734, filed on Oct. 29, 2003; U.S. application Ser. No.10/697,685, filed on Oct. 29, 2003; and U.S. application Ser. No.10/697,735, filed Oct. 29, 2003; each of which is a continuation-in-partof U.S. application Ser. No. 10/418,595, filed on Apr. 17, 2003; whichclaims the benefit of U.S. Provisional Application Ser. No. 60/374,601,filed Apr. 22, 2002; and U.S. Provisional Application Ser. No.60/426,438, filed Nov. 14, 2002.

FIELD OF THE INVENTION

The present invention relates to the uniform delivery of treatmentmaterials in fabric article drying appliances such as tumble dryers.

BACKGROUND OF THE INVENTION

Traditionally when applying treatment materials to fabrics in a fabricarticle drying appliance such as a tumble dryer, it has been difficultto achieve a uniform distribution of the treatment material onto thefabric. If the distribution of the treatment material is not uniform,this results in areas of the fabric being left untreated. This unevendistribution further results in undesirable fabric attributes which caninterfere with such things as the look, touch, smell, and longevity ofthe fabric. Additionally, in many instances, it has also been observedthat rather than being desirably deposited onto the fabric, thetreatment material ends up elsewhere such as being lost through thefabric article drying appliance vent. Hence, not only is uniformdistribution of the treatment material on the fabric important, but alsoproviding efficient delivery of the treatment material to the fabricsuch that the treatment material ends up on the fabric and notelsewhere.

Accordingly, there is a need to provide a convenient and effective wayof uniformly and efficiently delivering treatment materials to fabricsin a fabric article drying appliance. The present invention addressesthis need.

SUMMARY OF THE INVENTION

In one aspect, the present invention relates to a system for sprayingfabric in a fabric article drying appliance. The system comprises:

a) a tumble dryer; and

b) a spray for spraying a treatment composition onto fabric in thetumble dryer wherein the spray has:

-   -   i) a mean droplet size of the treatment composition of about 100        to about 1000 microns;    -   ii) a spray cone angle in the tumble dryer of about 35° to about        150°;    -   iii) a flowrate at the point the spray enters the tumble dryer        of about 0.5 ml/min to about 100 ml/min; and    -   iv) a linear velocity at the point the spray enters the tumble        dryer of about 0.5 m/second to about 20 m/second.

In another aspect, the present invention may comprise a device fordepositing benefit composition in a fabric article drying appliance. Thedevice comprises a pump wherein the pump comprises a conduit having aninlet and a discharge and a nozzle having one or more orifices connectedto the discharge of the conduit. The inlet of the conduit is incommunication with a source of a benefit composition so as to dispensethe benefit composition through the conduit to the nozzle whereby thebenefit composition has a mean droplet size of from about 100 microns toabout 1000 microns and wherein the cone angle formed by the benefitcomposition that is discharged from the nozzle is between about 35° andabout 150°.

In a further aspect, the present invention relates to a device whichprovides uniform distribution of a treatment composition on fabric in afabric article drying appliance. The device comprises a fabric articletreating device wherein the fabric article treating device is associatedwith the drum of a tumble dryer in a manner such that a benefitcomposition is dispensed from the fabric article treating device in theform of a spray into the drum wherein the spray contacts the fabric inthe drum so as to provide a uniformity of about 75% or more distributionof the benefit composition on fabric present in the drum.

In yet another aspect, the present invention relates to a method fordepositing benefit composition in the drum of a tumble dryer. The methodcomprises providing a pump comprising a conduit wherein the conduitincludes an inlet and discharge and a nozzle connected to the dischargeof the conduit. The inlet of the conduit is placed in communication withthe source of benefit composition wherein the inlet of the conduit is incommunication with the source of benefit composition. The benefitcomposition is dispensed through the conduit from the source of benefitcomposition to the nozzle and into the drum of a tumble dryer wherebythe benefit composition has a mean droplet size of from about 100microns to about 1000 microns, a linear velocity through the nozzle ofbetween about 0.5 m/second to about 2 m/second. The nozzle may bepositioned in the dryer drum in quadrant one, quadrant two, quadrantthree, quadrant four, or a combination thereof. The nozzle has a tiltangle wherein the tilt angle in quadrant one ranges from about 80° tothe left to about 45° to the right and from about 45° up to about 35°down; the tilt angle in quadrant two ranges from about 80° to the rightto about 45° to the left and from about 45° up to about 15° down; thetilt angle in quadrant three ranges from about 80° to the right to abut45° to the left and about 45° up to about 15° down; the tilt angle inquadrant four ranges from about 80° to the left to about 15° to theright and about 45° up to about 15° down; and combinations thereof.

In a further aspect, the present invention relates to a method forproviding efficient deposition of a benefit agent used to treat fabric.The method comprises providing a fabric article treating device and abenefit composition. The benefit composition is associated with thefabric article treating device such that the benefit composition isdischarged into the drum of a tumble dryer either before the tumbledryer is rotated, during rotation of the tumble dryer, or after rotationof the tumble dryer, or a combination thereof. The cone angle formed bythe benefit composition that is discharged into the tumble dryer isbetween about 35° to about 150°.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a dryer drum.

FIG. 2 is a perspective view of an embodiment of a stand-alone fabricarticle treating apparatus made according to the principles of thepresent invention.

FIG. 3 is a perspective view from the opposite angle of the fabricarticle treating apparatus of FIG. 2.

FIG. 4 is an elevational view from one end in partial cross-section ofthe fabric article treating apparatus of FIG. 2, illustrating theinternal housing and external housing, as joined together by a flatcable.

FIG. 5 is an elevational view from one side in partial cross-section ofthe internal housing portion of the fabric article treating apparatus ofFIG. 2.

FIG. 6 is a block diagram of some of the electrical and mechanicalcomponents utilized in the fabric article treating apparatus of FIG. 2.

FIG. 7 is a diagrammatic view in partial cross-section of the fabricarticle treating apparatus of FIG. 2, as it is mounted to the door of aclothes dryer apparatus.

FIG. 8 is a perspective view of a fabric article drying appliance thathas a nozzle which sprays a benefit composition into the drum portion ofthe dryer, as constructed according to the principles of the presentinvention.

FIG. 9 is a diagrammatic view of some of the components utilized by analternative embodiment stand-alone fabric article treating apparatusthat is constructed according to the principles of the presentinvention, in which the entire treating apparatus is contained within asingle housing or enclosure.

FIG. 10 is a perspective view of another embodiment of a stand-aloneunit for dispensing a benefit composition constructed according to theprinciples of the present invention.

FIG. 11 is a perspective view from an opposite angle of the unit of FIG.10.

FIG. 12 is an exploded view of the unit illustrated in FIGS. 10 and 11.

FIG. 13 is an exploded view of the fluid container, the first and secondfitments and the first and second mounting shelves.

FIG. 14 is a block diagram of at least a portion of the electrical andmechanical components utilized in the unit of FIGS. 11-13.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to the uniform distribution of treatmentmaterial onto fabrics in fabric article drying appliances such as tumbledryers. In another aspect, the invention relates to efficientlydepositing the treatment materials on the fabric so that the materialsare deposited on the fabric and not elsewhere.

DEFINITIONS

As used herein, “fabric article” means an article that comprises afabric. Such articles include, but are not limited to, clothing, shoes,curtains, towels, linens, upholstery coverings and cleaning implements.

As used herein, “during a dryer cycle” means while the dryer isoperating.

As used herein, “treatment material” means a material or combination ofmaterials that can deliver benefits to a fabric article. Examples ofsuch benefits include but are not limited to; softening, crispness,water and/or stain repellency, refreshing, antistatic, anti-shrinkage,anti-microbial, durable press, wrinkle resistance, odor resistance,abrasion resistance, anti-felting, anti-pilling, dimensional stability,appearance enhancement such as color and whiteness enhancement,anti-soil redeposition, fragrance, enhanced absorbency, and mixturesthereof.

As used herein, “fabric treatment composition” means a composition thatcomprises one or more treatment materials. Suitable forms of fabrictreatment compositions include, but are not limited to, fluidicsubstances, such as liquids or gases, and solid compounds, suchparticles or powders.

As used herein, the terms “treatment material”, “treatment composition”,“fabric treatment composition” and “benefit composition” are usedinterchangeably.

As used herein, the articles “a”, “an”, and “the” when used in a claim,are understood to mean one or more of the material that is claimed ordescribed.

Unless otherwise noted, all component or composition levels are inreference to the active level of that component or composition, and areexclusive of impurities, for example, residual solvents or by-products,which may be present in commercially available sources.

Unless otherwise indicated, all percentages and ratios are calculatedbased on weight of the total composition.

Unless otherwise indicated, all measurements herein were performed at astandard atmospheric pressure of about 1 bar.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

Delivery System

In one aspect of the present invention, the delivery system is comprisedof a spray for delivering treatment materials to fabrics in a fabricarticle drying appliance such as a tumble dryer. The dryer drum istypically rotating during delivery of the treatment materials but mayalso be stationary during delivery. The spray comprises a treatmentcomposition. The treatment composition comprising the spray of thepresent invention has a mean droplet size of about 100 microns to about1400 microns, about 200 microns to about 1300 microns, about 300 micronsto about 1200 microns, or about 500 microns to about 1100 microns. Asuitable instrument for measuring droplet size is the Malvern particlesizer manufactured by Malvern Instruments Ltd. of Framingham, Mass.

The viscosity of the treatment composition comprising the spray, asmeasured at approximately 24° C. using a Model DV-II BrookfieldViscometer with a LV I spindle, is about 200 cps or less, about 100 cpsor less, or about 50 cps or less. The Brookfield Model DV-II viscometeris available from Brookfield of Middleboro, Mass. The static surfacetension of the treatment composition comprising the spray as measuredbetween approximately 20° C.-25° C. is about 3 to about 100 dynes/cm,about 4 to about 70 dynes/cm, or about 5 to about 40 dynes/cm. Asuitable instrument for measuring static surface tension is a KrussTensiometer, Model K12 manufactured by Kruss of Matthews, N.C.

The treatment composition may be sprayed through a nozzle and into thedrum of a fabric article drying appliance such as the drum of a tumbledryer. The nozzle typically will have a diameter of about 200 to about600 microns or about 250 to about 400 microns. A non-limiting example ofa nozzle suitable for this purpose is a pressure swirl atomizing nozzle.Non-limiting examples of suitable nozzles include the Cosmos 13 NBUnozzle manufactured by Precision Valve Corporation of Marietta, Ga., theWX12 and WD32 nozzles manufactured by Saint-Gobain Calmar USA, Inc. ofCity of Industry, Calif., and Seaquist Model No. DU-3813 manufactured bySeaquist Dispensing of Cary, Ill. The nozzle may be in association witha spraying device. The nozzle may be permanently attached or releaseablyattached to a spraying device. One non-limiting example of a releaseablyattached nozzle is a nozzle which is threaded such that it can easily beremoved from or placed in a spraying device. The nozzle may bedisposable. The spraying device may be free standing or it may beassociated with the drying appliance as discussed in further detailbelow.

It is desirable that the fabrics in the fabric article drying appliancenot come into direct contact with the nozzle while the nozzle isoperating as this may inhibit flow from the nozzle. Hence, it may bedesirable for the nozzle to include a deflector which deflects thefabric away from the nozzle. The deflector may surround all or a portionof the nozzle (for example the top portion of the nozzle). The degree ofextension of the deflector into the fabric article drying appliance isselected so as to insure that the deflector does not intercept the coneangle of the spray under normal use conditions. The deflector may bemade from any suitable material, non-limiting examples of which includeplastic, metal, Plexiglas, and the like. The deflector may be of anyshape provided that the shape selected does not negatively impact fabricintegrity during tumble drying process (i.e.; no sharp edges/corners orrough surfaces).

The placement of the nozzle and angle of the nozzle may be varied so asto optimize spray contact with the fabric in the tumble dryer. In orderto facilitate the determination of where the nozzle should be positionedin relation to optimizing spray contact with the fabric, the dryer drummay be divided into four equal quadrants as shown in FIG. 1. The fourquadrants (quadrant one 601, quadrant two 602, quadrant three 603, andquadrant four 604) are determined by the intersection of the x-axis 630and y-axis 640 of the dryer drum 600. The position of the nozzle 610 maythen be varied in relation to these quadrants. One non-limiting exampleof placement of the nozzle 610 within the quadrant may be along thequadrant bisection line 612 as shown for the second quadrant 602 in FIG.1.

The nozzle 610 may also be angled in either the left to right directionand/or the up to down direction. This angling of the nozzle is referredto herein as “tilt angle”. The tilt angle may vary from quadrant toquadrant. For instance, as viewed looking straight into the dryer drumfrom the door side of the dryer, in the first quadrant 601 the tiltangle may be from about 80° to the left to about 45° to the right and/orfrom about 45° up to about 35° down. In the second quadrant 602 the tiltangle may vary from about 80° to the right to about 45° to the leftand/or from about 45° up to about 35° down. In the third quadrant 603the tilt angle may vary from about 80° to the right to about 45° to theleft and/or about 45° up and about 15° down. In the fourth quadrant 604the tilt angle may vary from about 80° to the left to about 15° to theright and/or about 45° up and about 15° down.

The tilt angle is typically selected such that the nozzle is notdirectly aimed at the dryer vent/lint screen or at the top of the drum.Furthermore, it is generally desirable that the nozzle be angled suchthat the spray from the nozzle is delivered through the voidspace/tunnel created by the tumbling of the fabrics around the perimeterof the dryer drum so as to contact the fabrics at the bottom of therotating circle of fabrics. Also it may be desirable that the nozzle beangled such that the spray intercepts the fabrics being tumbled in thedryer as the fabrics drop from their highest vertical point to theirlowest vertical point during dryer drum rotation.

It may be desirable in some instances to utilize more than one nozzle.Each nozzle could be designed to spray concurrently or at differenttimes, flow rate, velocity, etc. than the other nozzle(s).

The flowrate of the spray in the drum of the fabric article dryingappliance such as a tumble dryer is about 0.5 to about 100 ml/minute,about 1 to about 75 ml/minute, about 2 to about 50 ml/minute, or about15 to about 25 ml/minute. One suitable method for determining flow rateis found in ASME/ANSI MFC-9M-1988, entitled “Measurement of Liquid Flowin Closed Conduits by Weighing Method”.

The linear velocity of the spray in the drum of the tumble dryer isabout 0.05 to about 2 m/second or about 0.1 to about 1 m/second. Thelength of the spray in the drum of the tumble dryer is from about 20% toabout 95% of the length of the drum as measured along the rotationalaxis of the drum. One suitable method for determining linear velocity isby utilizing Laser Doppler Anemometry such as described in “LaserDoppler and Phase Doppler Measurement Techniques” part of the“Experimental Fluid Mechanics” series, written by Albrecht, H. E.,Damaschke, N., Borys, M., and Tropea, C., 2003, XIV, 738, page 382.

The cone angle of the spray refers to the angle the spray forms as it issprayed into the drum of the tumble dryer. A method for determining coneangle is described below. The cone angle of the spray is about 35° toabout 150° or about 40° to about 110° or about 50° to about 90°.

Spraying Device

As previously indicated the present invention may include a sprayingdevice for delivering the benefit composition into the tumble dryer. Thespraying device may be a stand-alone device or it may be incorporatedinto the fabric article drying appliance. As used herein the term“spraying device” is used interchangeably with the term “fabric articletreating apparatus”. Non-limiting examples of suitable spraying deviceswhich may be used with the present invention are disclosed in thefollowing commonly assigned co-pending applications: U.S. PatentApplication Publication No. 2004/0259750, published on Dec. 23, 2004 andentitled “Processes and Apparatuses for Applying a Benefit Compositionto One or More Fabric Articles During a Fabric Enhancement Operation”;WO 2004/12007, published on Nov. 4, 2004 and entitled “Volatile MaterialDelivery Method”; U.S. Patent Application Publication No. 2004/0123490,published Jul. 1, 2004 and entitled “Fabric Article Treating Method andDevice Comprising a Heating Means”; U.S. Patent Application PublicationNo. 2004/0123489, published on Jul. 1, 2004 and entitled “ThermalProtection of Fabric Article Treating Device”; U.S. Patent ApplicationPublication No. 2004/0134090, published on Jul. 15, 2004 and entitled“Fabric Article Treating Device Comprising More Than One Housing”; U.S.Application Publication No. 2004/0025368, published on Jul. 29, 2004 andentitled “Fabric Article Treating Apparatus with Safety Device andController”; and U.S. Application Publication No. 2004/0025368,published on Feb. 12, 2004 and entitled “Fabric Article Treating Methodand Apparatus”.

In one aspect of the present invention, the spraying system is comprisedof a pump, a nozzle, a source of benefit composition, and a conduit asdescribed in further detail below. The conduit connects the source ofthe benefit composition to the pump whereby the benefit composition isdischarged through the nozzle of the pump into a tumble dryer.Alternatively, the conduit connects the source of the benefitcomposition to the pump whereby the benefit composition is transportedvia conduit between the pump and nozzle and then discharged into atumble dryer. It should be noted that the interior of the conduit may beof any shape, non-limiting examples of which include circular and/oroval shaped. It may also be desirable to include a check valve in theconduit before the nozzle. Non-limiting examples of minimum workingpressures for the check valve are from about 0.1 psi to about 2 psi orfrom about 0.5 psi to about 1 psi.

The pump may be manually operated, and/or the pump may be automated. Thepump may be mechanically driven, electrically driven, or a combinationthereof.

The spraying system may comprise: a housing or enclosure that contains asource of the fabric treatment composition, such as a reservoir or is incommunication with an external source of the fabric treatmentcomposition; an output device, such as a nozzle; a controller, such asan electronic control device with a processing circuit and input andoutput circuits; one or more sensors, such as a temperature sensor,light sensor, motion sensor, or the like; one or more input devices,such as a start switch and/or a keypad; one or more indicating devices,such as color lights or LED's; and a charging system if the fabrictreatment composition is to be electrostatically charged before (orwhile) being delivered.

Reference will now be made in detail to suitable embodiments of devicesfor delivering a fabric treatment composition in accordance with one ofthe aforementioned temperature or time profiles, an example of which isillustrated in the accompanying drawings, wherein like numerals indicatethe same elements throughout the views.

FIGS. 2-5 illustrate one embodiment of an exemplary spray system whichmay be used in the present invention.

Referring now to the embodiment of FIG. 2, a “stand-alone” controllerand dispenser unit (i.e., as a self-contained device), generallydesignated by the reference numeral 10, is illustrated as having twomajor enclosures (or housings) 20 and 50. In this embodiment, theenclosure 20 acts as an “inner housing” which is located in the interiorof a fabric article drying appliance (e.g., a clothes dryer), while theenclosure 50 acts as an “outer housing” that is located in the exteriorof the fabric article drying appliance. The enclosure 50 may be mountedon the exterior surface of the fabric article drying appliance door,however, it may instead be mounted on any exterior surface, non-limitingexamples of which include: the side walls, the top walls, the outersurface of a top-opening lid, and the like, including a wall or otherhousehold structure that is separate from the fabric article dryingappliance. Furthermore, the enclosure 20 may be mounted on any interiorsurface of the fabric article drying appliance, examples of whichinclude, but are not limited to: the interior surface of the door, thedrum of the fabric article drying appliance, the back wall, the innersurface of a top-opening lid, and the like.

Enclosure 50 may be permanently mounted to the exterior surface, orpreferably releasably attached to the exterior surface. Likewise,enclosure 20 may be permanently mounted to the interior surface, orreleasably attached to the interior surface. One configuration for suchan attachment is illustrated in FIG. 7, in which the door of the dryingappliance is generally designated by the reference numeral 15.

When mounted on the interior surface of the door, for example, theenclosure 20 may be constructed so as to have the appearance of being“permanently” mounted, such that it seems to be “built into” the door ofa dryer unit (or other type of fabric article drying appliance), withoutit actually being truly constructed as part of the fabric article dryingappliance. On the other hand, enclosure 20 perhaps may be more looselymounted near the door, or along side the interior surface of the door,much like one of the embodiments 10 as depicted in FIGS. 2-5 that“hangs” along a vertical door of the appliance. It will be understoodthat the term “door,” as used herein, represents a movable closurestructure that allows a person to access an interior volume of the dryerapparatus, and can be of virtually any physical form that will enablesuch access. The door “closure structure” could be a lid on the uppersurface of the dryer apparatus, or a hatch of some sort, or the like.

It should be noted that the treating apparatus 10 may be grounded by wayof being in contact with a grounded part of the fabric article dryingappliance such as by a spring, patch, magnet, screw, or other attachingmeans, and/or by arc corona discharge, or by way of dissipating residualcharge. One non-limiting way of dissipating the charge is by using anionizing feature, for example a set of metallic wires extending awayfrom the source. In many instances fabric article drying appliances suchas clothes dryers have an enameled surface. One method of groundingwould be to ground to the enameled surface of the fabric article dryingappliance by utilizing a pin that penetrates the non-conductive enamelpaint for grounding thereto. Another method of grounding to thenon-conductive surface of a fabric article drying appliance comprisesthe usage of a thin metal plate that is positioned between the fabricarticle drying appliance and the fabric article treating device whichserves to provide a capacitive discharge. Typical thickness of such aplate is from about 5 microns to about 5000 microns.

In FIG. 2, a discharge nozzle 24 and a “door sensor” 22 are visible onthe inner housing 20, which also includes a benefit composition-holdingreservoir 26 within an interior volume of the inner housing 20. Thereservoir 26 may be used to hold a benefit composition. The dischargenozzle 24 can act as a fluid atomizing nozzle, using either apressurized spray or, along with an optional high voltage power supply(not shown in FIG. 2) it can act as an electrostatic nozzle. The benefitcomposition can comprise a fluidic substance, such as a liquid or agaseous compound, or it can comprise a solid compound in the form ofparticles, such as a powder, or solid particles in solution with aliquid. Reservoir 26 can be of essentially any size and shape, and couldtake the form, for example, of a pouch or a cartridge; or perhaps thereservoir could merely be a household water line for situations in whichthe benefit composition comprises potable water.

The inner housing 20 and outer housing 50 are typically in electricalcommunication. In the embodiment of FIG. 2, a flat cable 40 (alsosometimes referred to as a “ribbon cable”) is run between the twohousings 20 and 50, and travels along the inner surface of the fabricarticle drying appliance door 15 (see FIG. 7, for example), over the topof the door 15, and down the exterior surface of the door 15.

FIG. 3 shows the same fabric article treating apparatus 10 from anopposite angle, in which the outer housing 50 is provided with an ON-OFFswitch at 56. The flat cable 40 is again visible in FIG. 3, and alongthe surface of the inner housing 20 visible in FIG. 3, a door mountingstrap 21 is visible. An end of the mounting strap is also visible inFIG. 2. Certainly other arrangements for attaching the inner housing 20to a dryer door 15 (or other interior surface) are available withoutdeparting from the principles of the present invention, non-limitingexamples of which include magnets, suction cups, and hooks.

Referring now to FIG. 4, the fabric article treating apparatus 10 isillustrated such that the reservoir 26 can be seen as an interior volumeof the inner housing 20. In the outer housing 50, a set of batteries 52can be seen, as well as a printed circuit board with electroniccomponents at 54. It will be understood that any type of electricalpower source could be used in the present invention, including standardhousehold line voltage, batteries, or even solar power.

Referring now to FIG. 5, some of the other hardware devices areillustrated with respect to the inner housing 20. In the embodiment ofFIG. 5, the discharge nozzle 24 acts as an electrostatic nozzle, andthereby is coupled with a high voltage power supply 28, by use of anelectrical conductor not shown in this view. As shown in FIG. 6, a quickdisconnect switch 34 is included for safety purposes, so that the highvoltage power supply 28 can be quickly shut down if necessary. A pump 30and a corresponding electric motor 32 are visible in FIG. 5. Some typeof pumping apparatus is used regardless as to whether the dischargenozzle 24 is producing a pressurized spray only, or an electrostaticspray that utilizes a high voltage power supply 28.

FIG. 6 provides a block diagram of some of the electrical and mechanicalcomponents that may be included in a fabric article treating apparatus10, suitable for use with the present invention. In this exampleembodiment, the high voltage power supply 28 is provided in the innerhousing 20, which will be used to electrically charge the fluid thatwill be dispensed through the discharge nozzle 24, thus making this anelectrostatic nozzle system. The inner housing 20 utilizes a generalbody or enclosure to contain the devices needed within the dryingappliance, and it will be understood that such components will generallybe subjected to relatively high temperatures during the treatment cycleof the drying appliance. Consequently, the more sensitive electroniccomponents will generally (but not always) be mounted in a differentlocation, such as in the outer housing 50.

The flat cable 40 will bring certain command signals and electricalpower into the inner housing 20, and will also receive electricalsignals from sensors mounted in the inner housing 20 and communicatethose sensor signals back to the outer housing 50. A power supplycontrol signal follows a wire 70 through the quick disconnect switch 34to the high voltage power supply 28. This signal can comprise a constantDC voltage, a constant AC voltage, a variable DC voltage, a variable ACvoltage, or some type of pulse voltage, depending on the type of controlmethodology selected by the designer of the fabric article treatingapparatus 10.

In one embodiment, the signal at 70 is a variable DC voltage, and asthis voltage increases, the output of the high voltage power supply 28will also increase in voltage magnitude, along a conductor 39 (e.g., awire) that is attached to an electrode 38 that carries the high voltageto the nozzle 24, or into the reservoir 26. The voltage impressed ontothe electrode 38 will then be transferred into the benefit composition.A constant output voltage DC high voltage power supply could optionallybe used instead of the variable output voltage power supply 28 of theexemplary embodiment.

Once the benefit composition is charged within the reservoir 26 it willtravel through a tube or channel 42 to the inlet of the pump 30, afterwhich the composition will be pressurized and travel through the outletof the pump along another tube (or channel) 44 to the discharge nozzle24. For use in the present invention, the actual details of the type oftubing used, the type of pump 30, and the type of electric motor 32 thatdrives the pump, can be readily configured for almost any type ofpressure and flow requirements. The electrical voltage and currentrequirements of the electric motor 32 to provide the desired pressureand flow on the outlet of the pump 30 can also be readily configured foruse in the present invention. Virtually any type of pump and electricmotor combination can be utilized in some form or another to create auseful device that falls within the teachings of the present invention,or a stand-alone pump can be used (i.e., without an associated electricmotor).

It should be noted that some types of pumps do not require separateinput and output lines or tubes to be connected thereto, such asperistaltic pumps, in which the pump acts upon a continuous tube thatextends through an inlet opening and continues through a dischargeopening of the pump. This arrangement is particularly beneficial for usewith electrostatically charged fluids or particles that are being pumpedtoward the discharge nozzle 24, because the tubing can electricallyinsulate the pump from the charged benefit composition. It should alsobe noted that an alternative pumping device could be used, if desired,such as a spring-actuated pumping mechanism. A non-limiting example of asuitable peristaltic pump is the Model 10/30 peristaltic pump, which maybe obtained from Thomas Industries of Louisville, Ky.

If desired, the fabric article treating apparatus 10 can be enhanced byuse of certain sensors, examples of which include but are not limited toa door (or lid) sensor 22, a motion sensor 36, a humidity sensor 46,and/or a temperature sensor 48.

FIG. 7 diagrammatically shows the general location of some of thecomponents of one of the stand-alone embodiments of the fabric articletreating apparatus 10 which may be used with the present invention. Asdiscussed above, the electronics 54 and the batteries 52 are locatedwithin the outer housing 50, which is electrically connected to a flatcable 40 that carries power supply and input/output signals between theouter housing 50 and the inner housing 20.

Contained within the inner housing 20 are the reservoir 26, pump 30,electric motor 32, high voltage power supply 28, discharge nozzle 24,and various sensors that may or may not be included for a particularversion of the treating apparatus 10. The electrical conductor 39 isdepicted, which carries the high voltage to the nozzle 24, and this isone configuration that could be alternatively used instead of carryingthe high voltage to the reservoir 26. The tubing 42 to the inlet of thepump is illustrated, as well as the tubing 44 from the outlet of thepump that provides the benefit composition to the nozzle 24. It shouldbe noted that the high voltage power supply 28 is strictly optionalwithin the teachings of the present invention; if spraydroplets/particles emitted from the nozzle 24 are not to beelectrostatically charged, then there is no need for a high voltagepower supply within the inner housing 20.

FIG. 8 illustrates an alternative embodiment for use with the presentinvention, which depicts a fabric article drying appliance generallydesignated by the reference numeral 110. In this mode of the presentinvention, the controller depicted in the stand-alone embodiment of theearlier figures is now integrated into the electronic control system ofthe drying appliance 110. A door 15 is illustrated in FIG. 8, which isthe normal point of access by a human user to the interior drum volumeof the drying appliance 110. A nozzle 24 is used to direct a benefitcomposition into the drum area, in which the drum is generallydesignated by the reference numeral 114. A supply pipe 44 brings thebenefit composition to the nozzle 24, through a control valve 120, thatcan have an ON/OFF push button 56, if desired.

FIG. 9 illustrates an alternative stand-alone embodiment of the presentinvention, generally designated by the reference numeral 150. Componentsillustrated in FIG. 9 include a reservoir (or chamber) 26, an optionalcharging component 39 (such as an electrode or other type of electricalconductor that transports a high voltage to the reservoir or to thenozzle), a discharge nozzle 24, a pump unit 30, and a set of batteries52. An electronic printed circuit board 54 is provided, which wouldtypically include a microcontroller or other type of control circuit.One or more sensors may be included in such a device, as depicted at thereference numeral 129, and may include a pressure sensor, a door sensor22, motion sensor 36, humidity sensor 46, and/or a temperature sensor48. In this embodiment 150, all of the components are enclosed in asingle housing, and the entire unit is positioned within a fabricarticle drying appliance, such as a conventional clothes dryer found ina consumer's home.

The “single-housing” stand-alone unit 150 of FIG. 9 can incorporate allof the electrical and electronic components that are described hereinwith respect to FIGS. 6-7.

In FIGS. 10-14, where like reference numerals indicate like elements, abenefit composition dispensing apparatus 1100 constructed in accordancewith a third embodiment of the present invention is illustrated. Theapparatus 1100 comprises two enclosures or housings 1120 and 1150.Enclosure 1120 defines an “inner housing” located in an interior of afabric enhancement apparatus such as a fabric article drying appliance,e.g., a clothes dryer (not shown in FIGS. 10-14), while the enclosure1150 defines an “outer housing” located outside of the fabric articledrying appliance. The fabric enhancement apparatus may also comprise alaundry apparatus or a laundry and drying apparatus. The enclosure 1150may be mounted on an exterior surface of the fabric enhancementapparatus door (not shown), such as by pressure sensitive, thermallystable adhesive foam strips (not shown). Alternatively, the enclosure1150 may be mounted on any other exterior surface of the fabricenhancement apparatus, non-limiting examples of which include: sidewalls, top walls, an outer surface of a top-opening lid, and the like.The enclosure 1150 may also be mounted on a wall or other householdstructure that is separate from the fabric enhancement apparatus.Furthermore, the enclosure 1120 may be mounted, such as by pressuresensitive, thermally stable adhesive foam strips (not shown), on anyinterior surface of the fabric enhancement apparatus, examples of whichinclude, but are not limited to: the interior surface of the door, adrum of the apparatus, the back wall, the inner surface of a top-openinglid, and the like.

As illustrated in FIGS. 10 and 11, the inner housing enclosure 1120comprises a main body 1121 comprising an integral front/side mainsection 1122 and a back plate section 1123 secured to the main section1122 via screws, adhesive, snap-fit elements or the like. The sections1122 and 1123 are preferably molded from a polymeric material. Housedwithin the main body 1121 may be the following elements: a dischargenozzle 24; a door sensor 22 for sensing ambient light when the door ofthe fabric enhancement apparatus is open such that the sensor 22 isexposed to ambient light; a motion sensor 36 (contained within the mainbody 1121 and not visible from outside the main body 1121); a humiditysensor 46 (not shown in FIGS. 10 and 11); and a temperature sensor 48.In this embodiment, the nozzle 24 is not combined with a high voltagepower supply. The nozzle 24 functions as a fluid atomizing nozzle so asto generate a pressurized spray.

Referring to FIGS. 10-12 and 15, the enclosure 1150 comprises a mainbody 1151 having a back wall 1151 a, a first inner compartment 1151 b,for storing varying lengths of unused cable 1140, to be described below,and a second compartment 1151 c, for storing a fluid pump 1130, a motor1132 for driving the pump 1130, batteries 52, a tube 1142 (to bediscussed below) and a portion of a tube 1144 (to be discussed below).The enclosure 1150 further comprises a cassette door 1152 pivotablycoupled to the main body 1151 such as by pins 1152 a (only one of whichis illustrated in FIG. 12), a printed circuit board 1160 a and a faceplate 1162. The printed circuit board 1160 a is housed between the mainbody 1151 and the face plate 1162. The face plate 1162 is coupled to themain body 1151 via screws, adhesive, snap-fit elements, or like couplingelements. The pivotable door 1152 comprises a pocket 1152 b forreceiving a fluid reservoir defined by a removable container 1170 filledwith a benefit composition, which composition may comprise any one ofthe benefit compositions discussed in this document or the documentsnoted herein. The container 1170 may be formed from a polymericmaterial, paper, foil, a combination of these materials or a likematerial. The door 1152 is releasably held in a closed position withinthe main body 1151 via first and second flex arms 1153, which arecoupled to the main body 1151.

Extending through corresponding openings in the face plate 1162 are anON-OFF switch 1266 c, a “refluff” key or switch 266 d, and a dial 266 a,which may comprise a potentiometer, which a user rotates to dial in adesired one of a strong, regular or light setting corresponding to astrong, regular or light benefit level to be provided by a benefitcomposition to at least one fabric article during a fabric enhancementoperation.

The cable 1140 is coupled to and extends between the enclosures 1120 and1150. The cable 1140 may run along the inner surface of the fabricenhancement apparatus door, over the top of the door, and down theexterior surface of the door. Any unused length of the cable 1140 can bemanually inserted into the first compartment 1151 b for storage.

The cable 1140 carries benefit composition from the fluid pump 1130 inthe outer enclosure 1150 to the nozzle 24 in the inner enclosure 1120,see FIG. 14, and electrical signals from the sensors 36, 22, 46 and 48mounted in the inner enclosure 1120 to a microcontroller 1160 mounted tothe printed circuit board 1160 a in the outer enclosure 1150.

A first fitment 1172 is mounted to the main body 1151 via first andsecond mounting shelves 1155 a and 1155 b, see FIGS. 12 and 13, and iscoupled to the tube or channel 1142 (not shown in FIG. 13), which, inturn, is coupled to the pump 1130. The first and second shelves 1155 aand 1155 b are positioned on opposing sides of a flange 1172 a of thefirst fitment 1172 and are snap fit, adhesively secured or boltedtogether so as to encompass the flange 1172 a. The assembly comprisingthe shelves 1155 a and 1155 b and fitment 1172 is mounted to the mainbody 1151 such that the shelves 1155 a and 1155 b are received within aslot 1151 d defined in the main body 1151. The fitment 1172 is insertedinto a second fitment 1170 a forming part of the fluid container 1170when the door 1152 is pivoted to its closed position and functions topierce or otherwise penetrate the container 1170 so as to provide apathway for the benefit composition to travel from the container 1170 tothe tube 1142. From the tube 1142, the benefit composition travels tothe inlet of the pump 1130, after which the composition is pressurizedand carried via the tube or channel 1144 (shown in FIG. 12), whichextends through the cable 1140, to the discharge nozzle 24, where thebenefit composition is discharged. In the illustrated embodiment, thepump 1130 and the motor 1132 comprises a single assembly, namely, apiezoelectric pump, one of which is commercially available from ParTechnologies, LLC, under the product designation LPD-30S. Other suitablepumps which can be used in this or other embodiments include but are notlimited to gear pumps and diaphragm pumps. One non-limiting example of asuitable diaphragm pump is model No. NF5RPDC-S with a DC motor availablefrom KNF Neuberger, Inc. of Trenton, N.J.

The types of control signals used to control the electric motor 1132 canvary according to the design requirements of the apparatus 1100, andsuch signals will travel to the motor 1132 via an electrical conductor1172. In the illustrated embodiment, the electrical signal travelingalong conductor 1172 comprises a pulse-width modulated (PWM) signalcontrolled by the microcontroller 1160. Of course, such a pulse-widthmodulated signal can also be generated by any appropriate controller orprocessor, or appropriate discrete logic.

As noted above, the enclosure 1150 comprises a second compartment 1151 cfor storing batteries 52, which may comprise two AA batteries. In theillustrated embodiment, the batteries 52 define a power source, whichprovide a DC voltage to a DC power supply 1158, see FIG. 14. An exampleDC power supply comprises an integrated circuit chip commerciallyavailable from Maxim Integrated Products under the product designation“MAX1724EZK50-T.” The DC power supply 1158 provides an output voltage tothe microcontroller 1160.

A suitable microcontroller 1160 is a microprocessor manufactured byAtmel Corporation and sold under the product designation Atmega48-16A1.Alternatively, the microcontroller 1160 may comprise a microprocessormanufactured by Atmel Corporation and sold under the product designationAtmega48-16AJ. Of course, other microcontrollers, microprocessors,controllers, or processors made by different manufacturers, or discretedigital logic could alternatively be used.

The microcontroller 1160 includes on-board memory and input and outputlines for analog and digital signals. The microcontroller 1160 also hasa serial port that can be interfaced to an optional programmer interfaceusing an RS-232 communications link. As noted above, the ON-OFF switch1266 c, and the refluff key 266 d are coupled to the microcontroller1160, see FIG. 14. As also noted above, the motion sensor 36, doorsensor 22, humidity sensor 46 and temperature sensor 48 generate signalsto the microcontroller 1160. As further noted above, the microcontroller60 generates a pulse-width modulated (PWM) signal to the pump motor 1132via the conductor 1172. An audio indicator 1300 is further coupled tothe microcontroller 1160 and functions to indicate that a drying cyclehas been completed, clothes have been treated with the benefitcomposition, an error occurred during the benefit composition dosingcycle or the benefit composition dispensing apparatus is out of fluid.The audio indicator 1300 is mounted to the printed circuit board 1160,see FIG. 12.

Further coupled to the microcontroller 1160 are first, second, third,fourth and fifth light emitting diodes 1400 a-1400 e, see FIGS. 11-13.The diodes are coupled to the face plate 1162 so as to be visible to anoperator when actuated, see FIG. 11. The first diode 1400 a is actuatedby the microcontroller 1160 when the apparatus 1100 is activated via theON-OFF switch 1266 c. The second diode 1400 b is actuated by themicrocontroller 1160 when the pump 1130 is pumping benefit compositionto the nozzle 24. The third diode 1400 c is actuated by themicrocontroller 1160 when the refluff key 266 d has been activated. Thefourth diode 1400 d is actuated by the microcontroller 1160 when thespraying operation has been completed for the corresponding fabricenhancement operation cycle. The fifth diode 1400 e is actuated by themicrocontroller 1160 to generate a warning signal when the container isout of fluid, or the fabric enhancement cycle has been interrupted,which latter event may be detected via the door sensor 22 sensing lightor the motion sensor 36 sensing no motion. The microcontroller 1160 maysense that the container 1170 is out of fluid by sensing a change in thecurrent drawn by the pump motor 1132.

Treatment Composition

A treatment material provides one or more fabric benefits including, butnot limited to, softness, anti-soil re-deposition, stain or waterrepellency, color or whiteness enhancement, fragrance, enhancedabsorbency, anti-static, anti-bacterial, wrinkle control, shape/formretention, and/or fabric abrasion resistance. Classes of materials thatcontain materials that can provide such benefits include, but are notlimited to, cationic materials, nonionic materials, other polymericmaterials, and particulate materials. Typically, the treatment materialis present, based on total composition weight, at one of the followinglevels, at least about 0.5 wt %, at least about 2 wt %, from about 4 wt% to about 90 wt %, from about 4 wt % to about 50 wt %, or from about 4wt % to about 10 wt %. Suitable treatment materials include but are notlimited to those disclosed in WO 2004/12007, published on Nov. 4, 2004and entitled “Volatile Material Delivery Method”; WO 00/24856, publishedon May 4, 2000 and entitled “Fabric Care Composition and Method”; U.S.Patent Application Publication No. 2005/0022311 published on Feb. 3,2005 and entitled “Fabric Article Treating System and Method”; U.S.Patent Application Publication No. 2005/0076534, published on Apr. 14,2005 and entitled “Fabric Article Treating Device and System with StaticControl”.

The fabric treatment composition used in conjunction with the presentinvention may include a perfume. The perfume may comprise at least about0.005 wt. %, about 0.005 wt. % to about 10 wt % or about 0.1 wt. % toabout 2 wt. % of a material such as a perfume that comprises at leastabout 30 wt. %, about 35 wt % to about 100 wt. %, about 40 wt % to about100 wt. % or about 40 wt % to about 70 wt. % of a perfume materialhaving a boiling point of less than or equal to about 250° C. at 1atmosphere; a fabric treatment material; an optional carrier and thebalance being one or more adjunct ingredients such as disclosed incopending application WO 2004/12007.

The fabric treatment composition used in conjunction with the presentinvention may also include from about 0.5 to about 20% of fabricsofteners or fabric hand modifiers non-limiting examples of whichinclude diester quaternary ammonium compounds, polyquaternary ammoniumcompounds, triethanolamine esterified with carboxylic acid andquaternized materials, amino esterquats, cationic diesters, betainesters, betaines, silicone or silicone emulsions comprising aminosilicones, cationic silicones, quat/silicone mixtures, functionalizedpolydimethyl siloxanes (“PDMS”), amine oxides, silicone co-polyols,cationic starches, sucrose fatty esters, polyethylene emulsions, andmixtures thereof.

The fabric treatment composition used in conjunction with the presentinvention may also include from about 0.1 to about 1.2% of antistaticagents non-limiting examples of which include polyanilines,polypyrroles, poly acetylene, polyphenylene, polythiophenes, ethoxylatedpolyethyleneimines, and various commercial materials such as STATEXANWP, STATEXAN HA, or STATEXAN PES (available from LanXess—a subsidiary ofBayer located in Leverkusen, Germany), ETHOFAT (available from AksoNobel of Arnhem, Netherlands), and mixtures thereof.

The fabric treatment composition used in conjunction with the presentinvention may also include from about 0.005 to about 1.5% of malodorcontrol agents non-limiting examples of which include substituted orunsubstituted cyclodextrins, porous inorganic materials, starch,olfactory odor blockers and mixtures thereof.

The fabric treatment composition used in conjunction with the presentinvention may also include from about 0.05 to about 0.5% ofpreservatives non-limiting examples of which include didecyl dimethylammonium chloride which is available under the tradeneme UNIQUAT® (fromLonza of Basel Switzerland), 1,2-benzisothiazolin-3-one, which isavailable under the tradename PROXEL® (from Arch Chemicals of Norwalk,Conn.), dimethylol-5,5-dimethylhydantoin which is available under thetradeneme DANTOGUARD® (from Lonza of Basel Switzerland),5-Chloro-2-methyl-4-isothiazolin-3-one/2-methyl-4-isothiazolin-3-one,which is available under the tradename KATHON® (from Rohm and Haas ofPhiladelphia, Pa.), and mixtures thereof.

The fabric treatment composition used in conjunction with the presentinvention may also include from about 0.05 to about 5% of ethoxylatedsurfactants and/or emulsifiers. These may include, but are not limitedto carboxylated alcohol ethoxylates, ethoxylated quaternary ammoniumsurfactants, ethoxylated alkyl amines, alkyl phenol ethoxylates, alkylethoxylates, alkyl sulfates, alkyl ethoxy sulfates, polyethyleneglycol/polypropylene glycol block copolymers, fatty alcohol and fattyacid ethoxylates, long chain tertiary amine oxides, alkylpolysaccharides, polyethylene glycol (“PEG”) glyceryl fatty esters andmixtures thereof.

Processes of Making Fabric Treatment Compositions

The fabric treatment compositions of the present invention can beformulated into any suitable form and prepared by any process chosen bythe formulator, non-limiting examples of which are described in U.S.Pat. No. 6,653,275.

Uniformity and Deposition Efficiency

It is desirable that a treatment composition applied during the dryingprocess be uniformly distributed onto the fabric in the tumble dryerduring the drying process. It is also desirable during the dryingprocess that a treatment composition be deposited on the fabric that isin the tumble dryer rather than deposited elsewhere such as through thedryer vent/lint screen. While not wishing to be limited by theory it isbelieved that some factors which may possibly influence both uniformityof distribution and deposition of the treatment composition onto thefabric in the drum of the tumble dryer include flowrate of the treatmentcomposition in the drum, the droplet size of the treatment composition,the position of the spray in the drum, the cone angle of the spray inthe drum, the linear velocity of the treatment composition in the drum.

In accordance with the present invention, it is desirable that theuniformity of distribution (i.e.; Distribution Index) of the treatmentcomposition on the fabric in the drum of the tumble dryer be at leastabout 35%, at least about 45%, at least about 50%, at least about 60%,at least about 70%, at least about 75%, or at least about 80%. It isdesirable that the deposition of the treatment composition onto thefabric in the drum of the tumble dryer be at least about 70%, at leastabout 75%, or at least about 80%. It is also desirable that less thanabout 10% of the treatment composition be released from the dryer drumthrough the lint screen, less than about 5% of the treatment compositionbe released from the dryer drum through the lint screen, or less thanabout 1% of the treatment composition be released from the dryer drumthrough the lint screen.

Method for Determining Cone Angle of a Spray

The following method may be used to measure the cone angle (width of aspray).

1. Measure the depth of the dryer drum to which the spray is to beapplied. Calculate the distance that is 20% of the total length of thedryer drum depth.2. The sprayer which is to be the source of the spray is mounted on avertical surface at the height that corresponds to the vertical midpointof the dryer drum with the nozzle of the spraying device aligned withthe corresponding horizontal (perpendicular) axis.3. Assemble a Photron Fastcam PCI2KC available from Motion Engineeringof Indianapolis, Ind. in conjunction with a Magma CB2 and Dell Inspiron8100. Assemble a halogen lamp to provide additional light when filming.Use a 25 mm lens to video tape the spray with high resolution. Align thevideo camera such that the field of view includes the discharge of thenozzle and extends to at least the 20% distance calculated in step 1.Further, insure that the camera is aligned to capture the widest angleof the spray.4. Activate the spray in the absence of dryer airflow.5. Video tape the fluid spray at 1000 frames per minute against a blackbackground.6. Insert single frame pictures of the spray into Microsoft Visiowherein the pictures are zoomed in to 400%7. To determine the cone angle using the picture from step 6, draw thevertical line corresponding to the point that is 20% of the lengthdetermined in step 1 so as to intersect the top and bottom boundaries ofthe spray. From the point where the vertical line intersects the topboundary of the spray, draw a line back to the discharge midpoint of thenozzle of the sprayer. Repeat this process for the lower boundary of thespray (i.e.; from the point where the vertical line intersects thebottom boundary of the spray, draw a line back to the discharge midpointof the nozzle of the sprayer. The cone angle is the internal angleformed by the intersection of these two lines at the nozzle discharge.

Method for Determining Deposition of the Treatment Composition on theFabric and Deposition of the Treatment Composition on the Lint Screen

Fabric Stripping:

-   -   1. Weigh fabrics until the total load weight is approximately        2.7 kg.    -   2. Turn on the washing machine set on a 10-min. agitation time        and a high water level, approximately 21 gal fill.    -   3. Use approximately 160 grams of a liquid laundry detergent        such as Liquid TIDE®.    -   4. Add the detergent to the washing machine water after it is        approximately % full. Rinse the laundry detergent bottle cap out        with water running into the machine so as to allow any remaining        detergent in the cap to run into the washing machine.    -   5. Once the tub is filled to approximately ¾ full, the fabrics        are added to the water in the washing machine.    -   6. The wash cycle is allowed to proceed automatically through        completion of the final spin.    -   7. Steps #2-6 are repeated 3 more times, with the respective        amounts of detergent added to the wash load as listed above.    -   8. After the 4^(th) cycle is complete, the fabrics are removed        from the washing machine and dried using the high heat cycle of        a dryer.    -   9. The fabrics are then stored in plastic bags until treatment.

Fabric Treatment:

Fabric Load—Each treatment consists of using twelve 1 yd. squares ofstripped fabric swatches per load.Treatment Process—The stripped fabric swatches are placed in the washingmachine, set on the rinse cycle, wet and spun dry.Before placing damp fabrics into the tumble dryer, the following DryerCleaning Procedure is performed before each treatment. A 5% bleachsolution is sprayed inside the dryer on the front and back walls and thedryer drum. The lint screen is removed prior to spraying. The dryer isthoroughly wiped down with paper towels. Once dryer cleaning iscomplete, the lint trap of the dryer is replaced and covered with a new14″ by 7″ piece of white cotton knit fabric secured on the edges bymasking tape. A suitable white cotton knit fabric is CW120 availablefrom Empirical Manufacturing Company of Cincinnati, Ohio. The dampfabrics are then placed into the dryer drum, and a drying cycle iscompleted. During the drying cycle, a spray composition is deliveredinto the dryer drum. Following the drying treatment cycle, the fabricsare removed from the dryer drum as is the covering over the lint screenfor sampling and analysis.

Fabric Sampling:

Lint screen—The fabric over the lint screen is sampled as follows:

-   -   1. The covering over the lint screen is sampled by removing it        from the lint screen.    -   2. Six circular samples measuring 40 mm in diameter are cut from        the portion of the lint screen cover which was not covered by        the masking tape.    -   3. The six samples cut from the lint screen cover are labeled        and analyzed according to the swatch analysis described below.        Fabric Load (from the dryer)—    -   1. Six of the twelve, one square yards of fabric are sampled        from each cycle.    -   2. Each fabric swatch is unfolded and a ruler used to measure in        six inches from the corner of the swatch.    -   3. A 40 mm circle is cut from this area.    -   4. Sample swatches are labeled and analyzed.

Swatch Analysis:

Inductively Coupled Plasma Optical Emission Spectrometry (ICP) is usedto analyze the samples. In order to determine spray performance, Yttrium(Y) is spiked into the treatment composition solution as a tracerelement. Add 200 ppm of Y into the treatment composition to be tested.Spray the composition onto the fabric to be tested. After spraying, cutsamples from the fabric. Digest the fabric samples via high pressuremicrowave to get into acidic solution. Calibrate ICP for quantitative Ydetermination. Measure Y in solution. Back calculate for amount of Y onfabric and apply stoichiometric correction to determine amount oftreatment composition solution on the fabrics. The distribution of Y isrepresentative of the distribution of the treatment compositionsolution.

Method for Determining Uniformity of the Treatment Composition(Distribution Index) onto the Fabric

Image analysis may be used to evaluate uniformity of spray distributionper surface area of a test sample. A number of digital images areacquired per sample by imaging equipment and analyzed by computersoftware. The software detects a spray deposition area and provides acount of the number of pixels comprising the stained areas in the image.By comparison of the number of pixels detected for all images taken persample, a standard deviation is calculated. A smaller standard deviationcorrelates to a more uniform spray deposition. In order to determinespray uniformity, a fabric sample is sprayed with red dye (i.e.; 0.0 wt5% FD&C Red Dye #40 in distilled water).

Image analysis is then conducted according to the following steps toevaluate the uniformity of distribution of spray on a sample.

(1) Background Calibrate Imaging System and Acquire Digital Image ofSample

Background calibration, a well known technique for calibrating imagesusing a flat neutral gray card, is applied to images before analysis toeliminate lighting variance across the field of view and minimizeproblems in image analysis due to spatial lighting variance.Additionally, to insure color consistency in the digital images taken atdifferent times (e.g. images taken on different days), the images arealso color corrected using a standard color chart (Gretag Macbeth 24color chart).

After calibrating the background, place the fabric to be tested in alight booth and fold such that the particular area to be imaged is atthe center of the light booth directly between the lamps and facingupwards towards the camera. A stencil in the size of the field of viewof the camera (16 cm by 20.5 cm) is placed on the area to be imaged. Apicture is taken in response to a command from the operator when thesample is correctly positioned. Six images are taken per front-side andback-side of the fabric for a total of 12 images per fabric.

The picture is digitized (i.e. converted to a binary representation) ina known manner. Finally, the digital image data is transferred to acomputing device. Many other methods of acquiring the digital image arewell known to persons of ordinary skill in the art. For example, asample to be analyzed may be submitted via the network, a file may beretrieved from a database, and/or a flatbed scanner may be used todigitize a photograph.

(2) Electronically Analyze the Digital Image to Detect the Areas ofSpray Deposition

The image is electronically processed by image analysis software(Optimas v6.5 available from Media Cybernetics, Incorporated of SilverSpring, Md.) based on a reference intensity threshold. The region ofinterest selected is the entire screen image. The method for selectingthe intensity threshold setting is as follows. The background and colorcorrected images of the fabric (step 1 above) are converted to a single‘gray’ level image representation that highlights the difference betweenthe red dyed areas and ‘clean’ fabric areas. The method used dependsupon the lighting, imaging system, and type and color of dye used vs.the background fabric color. For example the green channel can be used.Related approaches can also be used, for example, an intensity imagefrom Red-Green, Red-Blue or other similar mathematical combinations ofthe Red, Green, and Blue color channels of an image can be used tocreate a single channel ‘gray’ level image for thresholding thataccentuates the differences between the dyed and ‘clean’ areas of thefabric.

The software is calibrated to detect colored areas in pixels of thedigital images. To set the threshold for pixel detection, a “clean”,un-dyed white fabric is the standard reference and is imaged accordingto step (1). After converting to a single channel ‘gray’ level imagerepresentation, the threshold is set for which zero pixels are detectedfor all images for that “clean” sample, and such that increasing thethreshold value any higher would make the software start detectingpixels on the “clean” sample. Pixels of a color intensity value withinthe set threshold are detected and counted by the image analysissoftware.

(3) Calculate Standard Deviation in Percent of Pixels Detected for allImages Per Sample

The percent of pixels detected per area is obtained by mathematicalcalculation using the number of pixels detected divided by the number oftotal pixels per image. Therefore for each fabric analyzed, there aretwelve values of percent of pixels detected. For the twelve images perfabric, the standard deviation of percent of pixels detected is obtainedby mathematical calculation, according to

$\sigma = \sqrt{\frac{\sum\limits_{i}\left( {X - \mu} \right)^{2}}{N - 1}}$

whereσ=standard deviationX_(i)=percent of pixels detected per imageμ=average value of the percent of pixelsN=number of values in the set of measurementsTo more conveniently compare the uniformity of spray deposition acrossfabrics, treatments, and the like, a Distribution Index is created by amathematical equation using the standard deviation value. Thisdistribution index is a scale from 0 to 100.

0<Distribution Index≦100

${{Distribution}\mspace{14mu} {Value}} = {\frac{1}{\left( {\sigma + 1} \right)} \times 100}$

Wherein a higher distribution value correlates to a more uniform sample.

EXAMPLES Example Treatment Composition

The following are non-limiting examples of treatment compositions whichmay be useful in the present invention:

Weight % CHEMICAL NAME A B C D E F G H Di- 6.500 2.17tallowoylethanolester dimethylammonium chloride Sucrose fatty ester2.000 0.67 Propylene glycol 2.000 2.00 n-butyl ether Propylene Glycol4.000 4.00 Diethylene Glycol 0.10 0.10 0.10 0.10 0.10 Hydrogenatedcastor 0.20 0.20 0.20 0.20 0.20 0.20 oil Ethoxylated 0.50 0.50 0.50 0.500.50 0.50 polyethyleneimine Phenoxyethanol 0.100 0.10 Preservatives 0.100.10 0.10 0.10 0.10 0.10 0.10 0.10 Stabilizers 0.100 0.20 0.20 0.20 0.200.20 0.20 0.20 Perfume 0.350 0.35 0.35 0.35 0.35 0.35 0.35 0.35Poly(oxy)ethylene 0.035 0.035 Lactic Acid 0.100 0.10 CaCl2•6H2O 0.2100.21 Silicone co- 0.100 0.10 polyol* Silwet L7600 0.05 0.05 0.05 0.05Silwet L7608 1.25 2.50 2.50 1.00 1.25 Silwet L 7001 Acetylenic diols1.00 Polyethylene 0.25 1.25 microemulsion Hydroxy propyl 0.25 0.25 0.250.25 0.25 cyclodextrin Deionized Water Balance Balance Balance BalanceBalance Balance Balance Balance TOTAL 100% 100% 100% 100% 100% 100% 100%100%

Weight % CHEMICAL NAME I J K L M N O Di-tallowoylethanolester 1.00 2.1712.00 dimethylammonium chloride Sucrose fatty ester 0.35 0.67 4.00Propylene glycol n-butyl ether Propylene Glycol Diethylene Glycol 0.100.10 Hydrogenated castor oil 0.20 0.10 0.20 0.40 0.40 Ethoxylatedpolyethyleneimine 0.50 1.00 0.50 0.50 Phenoxyethanol 0.10 0.10 0.200Preservatives 0.10 0.10 0.10 0.10 0.10 0.10 0.10 Stabilizers 0.20 0.200.20 0.100 0.20 0.20 0.20 Perfume 0.35 0.35 0.35 0.700 0.35 0.70 0.70Poly(oxy)ethylene 0.035 0.035 0.50 Lactic Acid 0.10 0.10 0.100CaCl2•6H2O 0.10 0.21 0.210 Silicone co-polyol* 0.10 Silwet L7600 SilwetL7608 0.05 0.05 0.05 0.05 0.05 Silwet L 7001 0.50 0.65 1.25 1.25 1.25Acetylenic diols 1.00 1.00 1.00 Polyethylene microemulsion 0.75 Hydroxypropyl cyclodextrin 0.25 0.25 0.25 0.25 Deionized Water Balance BalanceBalance Balance Balance Balance Balance TOTAL 100% 100% 100% 100% 100%100% 100%

Example Nozzle Placements

The following are non-limiting examples of nozzle placements which maybe used in a tumble dryer:

A. Non-limiting examples of nozzle placements which may be used with across-flow tumble dryer (i.e.; where the drum typically rotates in acounter-clockwise motion, and air flow typically enters the tumble dryerthrough a rear panel in quadrant 602 and exits through the rear panel ofthe dryer in quadrant 601—see FIG. 1).

Example 1 2 3 4 5 6 7 8 9 10 11 12 13 Number of 1 1 1  1  1  1  1  1 2 2 1  1 2 nozzles Dryer panel¹ F F F F F F F F F F B B F/B Quadrant² O O O 2  2  3  3  1  1/2  2/4  2 O  2/O Vertical 0 0 0 40 10 30  5 30 15/3040/20 30  0 25/0 displacement³ (%) Horizontal 0 0 0 20 30 10  5 20 10/1540/5 10  0 20/0 displacement⁴ (%) Nozzle angle 0 30 D 15 U 45 D 0 10 U55 U 30 D 45/15 0/15/U 25 D  5 D 15/15 (degrees up D/D D/D (“U”) or down(“D”)) Nozzle angle 0 20 L 55 L 15 R 5 R 15 R 25 L 45 L 45/0 30/45 10 R15 L 0/10/L (degrees left L/ R/L (“L”) or right (“R”))⁵ ¹Denotes nozzleplacement on the front (“F”) panel/door of the tumble dryer or back(“B”) panel of the tumble dryer. ²Abbreviated as follows: Referring toFIG. 1, “O” refers to the intersection of line 640 with line 630. Thenumber “1” refers to the first quadrant 601. The number “2” refers tothe second quadrant 602. The number “3” refers to the third quadrant603. The number “4” refers to the fourth quadrant 604. ³Expressed as %of the total distance from the intersection of lines 630 and 640 to theedge of the dryer drum (i.e.; the radius) when measured from theintersection of line 630 and line 640 along line 640 in the directionrequired to land in the designated quadrant. ⁴Expressed as % of thetotal distance from the intersection of lines 630 and 640 to the edge ofthe dryer drum (i.e.; the radius) when measured from the intersection ofline 630 and 640 along line 630 in the direction required to land in thedesignated quadrant. ⁵Referenced as viewed from the front side of thedryer.B. Non-limiting examples of nozzle placements which may be used with anaxial flow dryer (i.e.; where the drum typically rotates in a clockwisemotion and air flow typically enters the dryer through the rear panel ofthe appliance in the first quadrant 601 of FIG. 1 and exits through thelint screen in the front panel of the dryer below the door).

Example 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Number of 1  1  1  1  1  1  1 1  1  1 2 2 1 1 Nozzles Dryer panel¹ F F F F F F F F F F F/B B BQuadrant² O O O  1  1  1  2  2  3  4  1/2  1/1 2 O Vertical 0  0  0 3015  5 40  5 10 10 25/10 40/15 20 0 displacement³ (%) Horizontal 0  0  040 20  5 20  5 20 20 10/15 20/10 10 0 displacement⁴ (%) Nozzle 0 U 55 D55 D 35 D  0 15 U 30 D 10 D 55 U 45 U 0/15/D 15/0 20 U 15 D angle D/(degrees up (U) or down (D)) Nozzle 0 55 R  0 45 L 30 L  0 40 R 10 R 15R 35 L 0/45/R 30/5 15 R 25 R angle L/R (degrees left (L) or right (R))⁵¹Denotes nozzle placement on the front (“F”) panel/door of the tumbledryer or back (“B”) panel of the tumble dryer. ²Abbreviated as follows:Referring to FIG. 1, “O” refers to the intersection of line 640 withline 630. The number “1” refers to the first quadrant 601. The number“2” refers to the second quadrant 602. The number “3” refers to thethird quadrant 603. The number “4” refers to the fourth quadrant 604.³Expressed as % of the total distance from the intersection of lines 630and 640 to the edge of the dryer drum (i.e.; the radius) when measuredfrom the intersection of line 630 and line 640 along line 640 in thedirection required to land in the designated quadrant. ⁴Expressed as %of the total distance from the intersection of lines 630 and 640 to theedge of the dryer drum (i.e.; the radius) when measured from theintersection of line 630 and 640 along line 630 in the directionrequired to land in the designated quadrant. ⁵Referenced as viewed fromthe front side of the dryer.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention. All documentscited herein are, in relevant part, incorporated herein by reference.The citation of any document is not to be construed as an admission thatit is prior art with respect to the present invention.

1. A method for depositing benefit composition in the drum of a tumble dryer, the method comprising: a) providing a pump, the pump comprising a conduit wherein the conduit includes an inlet and a discharge and a nozzle connected to the discharge of the conduit; b) placing the inlet of the conduit in communication with the source of benefit composition wherein the inlet of the conduit is in communication with a source of benefit composition; c) dispensing the benefit composition through the conduit from the source of benefit composition to the nozzle and into the drum of the tumble dryer whereby the benefit composition has a mean droplet size of from about 100 microns to about 1000 microns, a linear velocity through the nozzle of between about 0.05 m/second and about 2 m/second, and wherein the nozzle is positioned in the dryer drum in quadrant one, quadrant two, quadrant three, quadrant four, or a combination thereof, and wherein the nozzle when present in quadrant one has a tilt angle ranging from about 80° to the left to about 45° to the right and from about 45° up to about 35° down; when present in quadrant two the nozzle has a tilt angle ranging from about 80° to the right to about 45° to the left and from about 45° up to about 15° down; when present in quadrant three the nozzle has a tilt angle ranging from about 80° to the right to about 45° to the left and from about 45° up to about 15° down; when present in quadrant four the nozzle has a tilt angle ranging from about 80° to the left to about 15° to the right and from about 45° up to about 15° down, and combinations thereof.
 2. A method for providing efficient deposition of a benefit agent used to treat fabric, the method comprising: a) providing a fabric article treating device; b) providing a benefit composition; c) associating the fabric article treating device with the benefit composition; d) discharging the benefit composition from the fabric article treating device into the drum of a tumble dryer whereby at the discharge of the fabric article treating device the benefit composition has a cone angle between about 35° and about 150°; and e) rotating the tumble dryer concurrent with step d, before step d, after step d, or a combination thereof.
 3. The method of claim 2 further comprising providing a drum of a tumble dryer associated with the fabric article treating device such that the benefit composition is dispensed from the fabric article treating device into the fabric article drying appliance whereby about 95% or more of the benefit composition dispensed into the drum of the tumble dryer is deposited onto fabric in the tumble dryer.
 4. A method for depositing benefit composition in a fabric article drying appliance, the method comprising: a) providing a fabric article treating device, the fabric article treating device comprising a conduit wherein the conduit includes an inlet and a discharge and a nozzle connected to the discharge of the conduit; b) placing the inlet of the conduit in communication with the source of benefit composition wherein the inlet of the conduit is in communication with a source of benefit composition; and c) dispensing the benefit composition through the conduit from the source of benefit composition to the nozzle and into the interior of a fabric article drying appliance whereby the uniformity of distribution of the benefit composition onto fabric is at least about 45%.
 5. The method of claim 4 wherein less than about 10% of the benefit composition is released from the interior of the fabric article drying appliance through a lint screen.
 6. The method of claim 4 wherein the benefit composition is electrostatically charged.
 7. The method of claim 4 wherein about 95% or more of the benefit composition dispensed into the interior of the fabric article drying appliance is deposited onto fabric. 